Carrier sheet and method of using the same

Abstract

A carrier sheet for providing support to a photocurable printing blank as the photocurable printing blank is conveyed through a plurality of laminating rollers that laminate an oxygen barrier layer to a top surface of the photocurable printing blank. The carrier sheet includes a heat resistant dimensionally-stable backing layer; and a resilient layer mounted on the heat resistant dimensionally-stable backing layer.

What is claimed is: 
     
       1. A method of laminating an oxygen barrier layer to a surface of a flexographic printing blank prior to exposure of the printing blank to actinic radiation to selectively crosslink and cure the flexographic printing blank and create a relief image therein, wherein the flexographic printing blank comprises an in situ mask, and a photocurable layer disposed on a support sheet, the method comprising the steps of:
 a) positioning the flexographic printing blank on a carrier sheet such that the carrier sheet supports the flexographic printing blank, wherein the carrier sheet comprises:
 i) a heat resistant dimensionally-stable backing layer; and 
 ii) a resilient layer mounted on, or adhered to, the heat resistant dimensionally-stable backing layer; and 
 
 b) passing the flexographic printing blank and the carrier sheet through at least one laminating roller to laminate an oxygen barrier membrane to a surface of the flexographic printing blank, wherein the oxygen barrier membrane covers the in situ mask and any uncovered portions of the photocurable layer. 
 
     
     
       2. The method according to  claim 1 , wherein the flexographic printing blank has a thickness of greater than about 4 mm. 
     
     
       3. The method according to  claim 1 , wherein the flexographic printing blank has a Shore A value of less than about 60. 
     
     
       4. The method according to  claim 3 , wherein the flexographic printing blank has a Shore A hardness of less than about 50. 
     
     
       5. The method according to  claim 1 , wherein at least one of the laminating rollers is maintained at a temperature of at least about 150° F. 
     
     
       6. The method according to  claim 1 , wherein the heat resistant dimensionally-stable backing layer comprises a thermoplastic polymer. 
     
     
       7. The method according to  claim 6 , wherein the thermoplastic polymer is a polycarbonate. 
     
     
       8. The method according to  claim 1 , wherein the heat resistant dimensionally-stable backing layer has a thickness of between about 0.050 and about 0.225 inches. 
     
     
       9. The method according to  claim 1 , wherein the resilient layer comprises a compressible layer. 
     
     
       10. The method according to  claim 9 , wherein the compressible layer comprises an open cell structure. 
     
     
       11. The method according to  claim 10 , wherein the compressible layer comprises an open cell microcellular urethane foam layer. 
     
     
       12. The method according to  claim 1 , wherein the resilient layer has a thickness of between about 0.020 and about 0.20 inches. 
     
     
       13. The method according to  claim 12 , wherein the resilient layer has a thickness of between about 0.035 and about 0.10 inches. 
     
     
       14. The method according to  claim 1 , wherein the resilient layer is bonded to the heat resistant dimensionally-stable backing layer.